Cellular structural material



Examine O6. COMPOSITIONS, g

COATING OR PLASTIC.

F I l a tented June 17, 193( r UNITED STATES PATENT; OFFICE HARRY E. BROOKBY AND GEORGE D. KING, OF CHICAGO, ILLINOIS, ASSIGNORS T0 UNITED STATES GYPSUM COMPANY, OF CHICAGO, ILLINOIS, A CORPORATION OF ILLINOIS CELLULAR STRUCTURAL MATERIAL No Drawing. Application filed May 8, 1925. Serial No. 28,942.

This invention relates to building matein the as within the lastic mass the coprials and more particularly to the producper m fifigmfihluble retion of a porous, cellular structural matetarder. In this way the finely divided solid rial. particles do not weaken the normal set gyp- It is an object of this invention to prepare sum structure as ordinary gypsum retarder a dry mixture including commercial calclned does. gypsum which when mixed with water to a Saponaceous, mucilaginous, gummy, glutplastic state will evolve a gas within the inous material substances giving a colloidal plastic mass causing it to expand to an ineffect as Well as commercial gypsum retard- 10 creased volume and in that condition first ers have heretofore been employed to encongeal and then harden without settling. train the gas in plastic mixtures but such In carrying out this invention a dry mixsubstances do not confine their influence or ture comprising commercial gypsum laster the gas evolution to the interfaces of the of Paris or its equivalent, We u mg c alclum cellular structure about the gas bubble. sulphate in such state that hardening from Such substances mentioned are also soluble plastic mixtures can be accomplished a carin water, will go into solution, and in solubonate yielding an alkaline reaction on hytion will interfere with the normal setting 7 r0 ysls, and a metal salt ivin in water of th gy um ba e, solution an acid reaction which chemically In accordance with this invention, this react releasln the as from the carbonatg film stren thenim a cut is precipitated 7 and precipi a mg a eriva ive 1n so 1 orm from one of the ingredients of the mixture is contemplated. \Vhen sufficient water is wh n wat r is added and being insoluble by added to make this mixture a multiattaching itself to the interfaces of th a plicity of gas bubbles or cells will be created tual film structure and through this rein- 25 within the mass by the evolution Of the gas forcement permits the Plastic mass to rereleased by this reaction upon the interact i it porous t 1 tion of the carbonate and salt, the Insoluble film strengthening agents rometal of h alt i p ec p a d as duce a much stronger structure than soluble combined solid which Wlll g0 into the intersubstances such as above referred to, as the 30 faces of the gas bubbles system and the'parti l of th film strengthening agent g fiCleS 0f the Solid p p t l film into the interfaces of the bubble or cellular embed themselv 11 the Surface Walls Of structure, that is, attach themselves to the the cellular structure increasing the viscost i r of the gypsum wall structure beity thickness of h Walls and thereby tween cells, and are found on the surfaces 35 retain the gas Within the p h mass While of these developed and hardened cell walls it is expanding until the ehhlre mass in the final hardened article when out gealsthrough for exposure. The calcined gypsum The Volume of the Plastlc massi 15 extra is not weakened and in hardening develops ordinarily increased by the evolution of the its full strength.

i= gas, and the bubbles are retained therein as The if formed as a dry Powder in on i fi i hardens accordance with this invention may be emt 110mg 1 he Se mg 0 3 ca cme gypsum ployed on the job, Where it is handled by to produce a firm, cellular structural mate- 1 rial adapted to be formed into desired shapes m hke h calclned, gypsum material, for coverlng structures 1n place,

45 when it is in the plastic state.

The hardening and setting of tho calcined m a factory h cast hhlt's are made for gypsum b proceeds ll as h fi l subsequent erection 1n the field. As an exdivided articles of co )er com ound are p 3 0111310 fool; of my P H m erlal precipita e rem 1e so u 1OI1 an 0 15'5 having a substantlal structurahvalue may mmfibhfim' fdfm be made from approximately thirty pounds of material having the following formula when mixed with water to a plastic state:

, Parts Calcined gypsum 100 Sodium carbonate 2 Copper sulphate proportion or ingredients above specified for denser structures may be made by varying the proportion of the ingredients; also other ingredients will satisfactorily liberate gas and other metal salts will precipitate the copper compound on the interfaces of the gas bubble system and embed the particles thereof in the walls of the cells making up the cellular structure to prevent the mass from settling without departing from the spirit and scope of this invention.

In our prior pending application Serial F") No. 22,183, filed April 10, 1925, for a composition of matter, and of which this application is a continuation, the broad invention of producing a cellular or porous structural building material by mixing commercial gypsum; a carbonate ielding an alkaline reaction on hydrolysis; a substance, preferably a metal salt, giving an acid reaction in water solution and a finely divided owdered charinsoluble solid, preferably coal. carbon 'ra )lnte talc mica or n divided silica which upon the additlon of wa er W1 evo ve a gas within and expand the plastic mass while the particles of the finely divided solid will go into the interfaces of the gas bubble system and film or imbed themselves on the surfaces of the walls of the cellular structure increasing the viscosity or thickness of such walls and thereby retaining until the entire mass congeals, hardens and sets, is fully set forth.

In this continuing application the finely divided solid, referred to in the prior application, is not added to the mixture as a separate ingredient. The finely divided solid is deposited upon the gas bubble cell wall in accordance with this invention by the chemical reaction between two of the ingredients of the mixture in the presence of water, while the gas is evolving, precipitating a copper compound thereon. The product resulting from this invention is on account of the nature of the finely divided solid, a much harder product than that specifically described in the said prior application.

What we claim. is:

1. The process for producing a cellular structure which consists in adding sufficient water to a mixture of commercial calcined gypsum, sodium carbonate and copper sulphate to render the mass plastic and allow a chemical reaction between the carbonate and sulphate to liberate a gas within the plastic mass and precipitate a copper compound upon the interfaces of the gas cell walls, and then allowing the mass to dry.

2. The process of producing a cellular structure from calcined gypsum which consists in mixing together one hundred parts of commercial gypsum with two parts of sodium carbonate, ten parts of copper sulphate and adding sufficient water to make the mass plastic and cause a chemical reaction to take place therein evolving a gas and filming the surfaces of the gas bubble cell structure with an insoluble solid, and then allowing the mass to dry:

3. A cellular structural material derived from calcined gypsum, sodium carbonate, copper sulphate, and sufficient water to render the mixture fluid causing the sodium carbonate and copper sulphate to react to evolve a gas within the plastic mass and deposit a copper compound upon the walls of the gas bubble cells Within the plastic mass.

4. A cellular structural material derived from substantially one hundred parts of calcined gypsum, two parts of sodium carbonate, ten parts of copper sulphate and suflicient water to render the mixture plastic causing the mass to expand and dry without settling.

5. A dry mixture comprising substantially one hundred parts of commercial gypsum, two parts of sodium carbonate and ten parts of copper sulphate, which substances upon the addition of water results in an expanded plastic cellular structure having the walls of the cells coated with a copper compound precipitated thereon during the evolution of a gas evolved by the reaction of the sodium carbonate and copper sulphate within the plastic gy )sum which, without chemically reacting with the other ingredients to aid in evolving the gas, congeals and hardens without settling from the expanded state.

HARRY E. BROOKEY. GEORGE D. KING. 

